Spotlight apparatus and manufacturing method thereof

ABSTRACT

A spotlight apparatus has a LED plate, a lens plate, a cup body, a driver plate and two metal pins. The lens plate has a central lens and a plurality of micro optical structures. The cup body has a dome portion, a tube portion and a bottom portion. The dome portion and the tube portion are manufactured together as a single body. A portion of light emitting from the LED plate runs through the central lens of the lens plate to form a focus light beam and another portion of light emitting from the LED modules running through the plurality of micro optical structures to form soft light. Two input terminals of the driver plate are inserted into the two metal pins.

FIELD OF INVENTION

The present invention is related to a spotlight apparatus andmanufacturing method thereof and more particularly related to a LEDspotlight apparatus and manufacturing method thereof.

BACKGROUND

Spotlight devices are widely used in various areas, including to bettershow a painting or a portion of a dinner table. However, spotlightdevices usually takes higher price and thus making them less adoptedthan needed. Current spotlight devices usually have more complicatedstructures and thus make them having higher cost.

Therefore, it would be a technical challenge to design a simplerstructure of spotlight device and would be even better if heatdissipation and assembling factors are also considered in such design.

SUMMARY OF INVENTION

According to a first embodiment of the present invention, a spotlightapparatus has a LED plate, a lens plate, a cup body and a driver plate.

The LED plate has a plurality of LED modules, a metal plate and twoconnectors. The plurality of LED modules and the two connectors aremounted on the metal plate. The LED modules may each be a single LEDchip or multiple LED chips formed as a module.

A lens plate has a central lens and a plurality of micro opticalstructures around the central lens. Different lens plate may be preparedfor generating spotlight apparatuses with different light beamcharacteristics while the other components kept unchanged.

Therefore, a detachable connection structure like screw or clips may bedesigned so that users may change a different lens plate to fit theirneeds. For example, a user may buy such spotlight apparatus with anumber of lens plates with different central lens settings. The user mayreplace the default lens plate with another lens plate, e.g. to emit amore wide light beam or a narrower light beam. In addition, differentcolors of lens plate may be designed so that users may change adifferent color filter to affect the light beam from such spotlightapparatus.

The cup body has a dome portion, a tube portion and a bottom portion.The dome portion and the tube portion are manufactured together as asingle body. The lens plate is fixed to a top peripheral end of the domeportion of the cup body. The LED plate is disposed inside the dormportion so that a portion of light emitting from the LED modules runningthrough the central lens of the lens plate to form a focus light beamand another portion of light emitting from the LED modules runningthrough the plurality of micro optical structures to form soft light.The plurality of micro optical structures may be designed to diffuse thelight or made of tiny cave, blocks or dots. The central lens may also bemade of multiple lens structures instead of a single lens.

The driver plate contains driver circuits, two output terminals and twoinput terminals.

The two metal pins are integrated to the bottom portion of the cup body.The two input terminals of the driver plate are inserted into the twometal pins and the two output terminals connected to the LED plate.

In a specific example, there is a neck portion between the dorm portionand the tube portion. There is a first distance between where the LEDplate is disposed and the neck portion. There is a second distancebetween the top peripheral and the neck portion. The first distance issmaller than half of the second distance and larger than one fourth ofthe second distance.

In another specific example, there are diffusion optical structuresformed on the dorm portion and the tube portion, e.g. to increaseoverall light output and to prevent visual exposing of the components ofthe spotlight apparatus.

In another specific example, the two metal pins have openingsrespectively for receiving the two input terminals of the driver plate.In other words, the two input terminals may not need to be welded butjust plugged into the metal pins. This helps significant decreasemanufacturing cost.

In another specific example, the two metal pins are metal hollow tubes.For example, the two metal pins are cylinder shape with central opening.

In another specific example, a portion of the input terminals of thedriver plate is deformed when the input terminals are inserted into theopenings of the two metal pins to keep better connection between theinput terminals and the two metal pins. The input terminal may be madewith elastic metal so that when the input terminals are plugged into themetal pins, the input terminals has form changing and increasing forceto fix to the metal pins.

In another specific example, the two metal pins are molded with thebottom portion of the cup body. For example, the metals are notconnected to the bottom portion of the cup body by screw structures.Instead, the metal pins are placed in a molding device while molding thebottom portion of the cup body.

In a specific example, the dome portion, the tube portion and the bottomportion of the cup body are together formed with Polycarbonate (PC)material as a single body. Please note that other plastic or materialmay be adopted if they allow light to go through.

In another specific example, the two metal pins are inserted in amolding device when the molding device is used for produce the cup bodyso that the two metal pins are molded with the bottom portion of the cupbody.

In a specific example, the lens plate is made of Polycarbonate materialas a single body. In other words, the cup body and the lens plate may bemade of same PC material thus making the overall cost even lower.

In a specific example, the tube portion of the cup body has a tracktrench for guiding and inserting the driver plate. With such design, thedriver plate may be reliably fixed to the tube portion of the cup body.

In a specific example, the driver plate has a base plate with metalmaterial for heat dissipation. For example, the base plate may be madeof aluminum.

To further increase heat dissipation, heat dissipation gel may beapplied between the track trench and the driver plate to enhance heatdissipation.

Alternatively, heat dissipation glue may be applied between the tracktrench and the driver plate to enhance heat dissipation and connectionreliability between the track trench and the driver plate.

In a specific example, the lens plate has a transparent hollow cupfacing the LED modules.

According to another embodiment of the present invention, a method formanufacturing a spotlight apparatus has following steps.

Two metal pins are placed in a molding device.

A cup body is formed with the molding device. The cup body has a dormportion, a tube portion and a bottom portion. In addition, the two metalpins are molded with the bottom portion.

A driver plate is placed in the cup body so that two input pins of thedriver plate are inserted into the two metal pins.

A LED plate is mounted on the driver plate so that two output terminalsof the driver plate are electrically connected to the LED plate.

A lens plate is placed to a top peripheral end of the dome portion ofthe cup body.

In a specific example of the method, the cup body is made ofPolycarbonate material.

In a specific example of the method, the tube portion of the cup bodyhas a track trench for guiding and inserting the driver plate.

In a specific example of the method, the metal pins two metal pins aretwo metal hollow tubes, and the two input terminals of driver plate areinserted into the two metal hollow tubes.

In a specific example of the method, the lens plate has a central lensand a plurality of micro optical structures so that a portion of lightemitting from the LED plate running through the central lens of the lensplate to form a focus light beam and another portion of light emittingfrom the LED plate running through the plurality of micro opticalstructures to form soft light.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates an exploded diagram of components of a spotlightapparatus embodiment according to the present invention.

FIG. 2A illustrates an embodiment of a lens plate.

FIG. 2B illustrates side view of FIG. 2A.

FIG. 3 illustrates a cup body embodiment.

FIG. 4 illustrates a diagram of metal pins and input terminals.

FIG. 5 is a side view of the spot light embodiment of FIG. 1 when thespotlight is assembled.

FIG. 6 is a flowchart for illustrating a method for manufacturing aspotlight apparatus.

DETAILED DESCRIPTION

Please refer to FIG. 1 and FIG. 5. FIG. 1 illustrates an explodeddiagram of components of a spotlight apparatus. FIG. 5 illustrates aside view of cross-sectional diagram of the components of FIG. 1 whenthey are assembled together.

The spotlight apparatus has a LED plate 103, a lens plate 101, a cupbody 105, a driver plate 104, a pair of screws 102 for fixing thecomponents.

The LED plate 103 has a plurality of LED modules, a metal plate and twoconnectors. The plurality of LED modules and the two connectors aremounted on the metal plate. The LED modules may each be a single LEDchip or multiple LED chips formed as a module.

Please refer to FIG. 2A and FIG. 2B, which illustrate a lens plateexample. In FIG. 2A and FIG. 2B, the lens plate is a circular shape andhas a central lens 201 and a plurality of micro optical structures 202around the central lens. Micro optical structures are patterns includingconcave or other structure that may guide or change light paths toachieve certain optical effect. FIG. 2B is a side view of FIG. 2A. Thelens plate 20 has a transparent hollow cup 203 structure for guidinglight entering the central lens 201. The central lens 201 may be made ofa single lens or multiple lens that generates the effect of creating aspotlight beam.

Different lens plate may be prepared for generating spotlightapparatuses with different light beam characteristics while the othercomponents kept unchanged.

Therefore, a detachable connection structure like screw or clips may bedesigned so that users may change a different lens plate to fit theirneeds. For example, a user may buy such spotlight apparatus with anumber of lens plates with different central lens settings. The user mayreplace the default lens plate with another lens plate, e.g. to emit amore wide light beam or a narrower light beam. In addition, differentcolors of lens plate may be designed so that users may change adifferent color filter to affect the light beam from such spotlightapparatus.

Please refer back to FIG. 1. The cup body 105 has a dome portion 1051, atube portion 1053 and a bottom portion, which facing to and integratedwith two metal pins 1054. The dome portion 1051 and the tube portion1053 are manufactured together as a single body. The lens plate 101 isfixed to a top peripheral end of the dome portion 1051 of the cup body105. The LED plate 103 is disposed inside the dorm portion 1051 so thata portion of light emitting from the LED modules running through thecentral lens of the lens plate 101 to form a focus light beam andanother portion of light emitting from the LED modules running throughthe plurality of micro optical structures to form soft light. Theplurality of micro optical structures may be designed to diffuse thelight or made of tiny cave, blocks or dots. The central lens may also bemade of multiple lens structures instead of a single lens.

The driver plate 104 contains driver circuits, two output terminals andtwo input terminals.

The two metal pins 1054 are integrated to the bottom portion of the cupbody 105. The two input terminals 1041 of the driver plate 104 areinserted into the two metal pins 1054 and the two output terminals 1042connected to the LED plate 103.

In a specific example, there is a neck portion 1052 between the dormportion and the tube portion.

Please also refer to FIG. 3. There is a first distance 302 between wherethe LED plate 312 is disposed and the neck portion 311. There is asecond distance 301 between the top peripheral 313 and the neck portion311. The first distance 302 is smaller than half of the second distance301 and larger than one fourth of the second distance 301. For example,the first distance 302 is about ⅓ of the second distance 301. Sucharrangement makes both light efficiency and heat dissipation for leavingspace for heat movement.

In another specific example, there are diffusion optical structuresformed on the dorm portion and the tube portion, e.g. to increaseoverall light output and to prevent visual exposing of the components ofthe spotlight apparatus.

In another specific example, the two metal pins have openingsrespectively for receiving the two input terminals of the driver plate.In other words, the two input terminals may not need to be welded butjust plugged into the metal pins. This helps significant decreasemanufacturing cost.

In another specific example, the two metal pins are metal hollow tubes.For example, the two metal pins are cylinder shape with central opening.

In another specific example, a portion of the input terminals of thedriver plate is deformed when the input terminals are inserted into theopenings of the two metal pins to keep better connection between theinput terminals and the two metal pins. The input terminal may be madewith elastic metal so that when the input terminals are plugged into themetal pins, the input terminals has form changing and increasing forceto fix to the metal pins.

In another specific example, the two metal pins are molded with thebottom portion of the cup body. For example, the metals are notconnected to the bottom portion of the cup body by screw structures.Instead, the metal pins are placed in a molding device while molding thebottom portion of the cup body.

In a specific example, the dome portion, the tube portion and the bottomportion of the cup body are together formed with Polycarbonate (PC)material as a single body. Please note that other plastic or materialmay be adopted if they allow light to go through.

Please refer to FIG. 4, which illustrates interaction between an inputterminal of a driver plate 401 and a metal pins 402. The front end ofthe input terminal is inserted into a hole of the metal pins 402. Inaddition, a deformation of the inserted portion of the input terminal401 would help fixing better for the input terminal 401 and the metalpins 402. In another specific example, the two metal pins are insertedin a molding device when the molding device is used for produce the cupbody so that the two metal pins are molded with the bottom portion ofthe cup body.

In a specific example, the lens plate is made of Polycarbonate materialas a single body. In other words, the cup body and the lens plate may bemade of same PC material thus making the overall cost even lower.

In a specific example, the tube portion of the cup body has a tracktrench for guiding and inserting the driver plate. With such design, thedriver plate may be reliably fixed to the tube portion of the cup body.

In a specific example, the driver plate has a base plate with metalmaterial for heat dissipation. For example, the base plate may be madeof aluminum.

To further increase heat dissipation, heat dissipation gel may beapplied between the track trench and the driver plate to enhance heatdissipation.

Alternatively, heat dissipation glue may be applied between the tracktrench and the driver plate to enhance heat dissipation and connectionreliability between the track trench and the driver plate.

In a specific example, the lens plate has a transparent hollow cupfacing the LED modules.

Please refer to FIG. 6, which is a flowchart illustrating a method formanufacturing a spotlight apparatus that has following steps.

Two metal pins are placed in a molding device (step 601).

A cup body is formed with the molding device (step 602). The cup bodyhas a dorm portion, a tube portion and a bottom portion. In addition,the two metal pins are molded with the bottom portion.

A driver plate is placed in the cup body (step 603) so that two inputpins of the driver plate are inserted into the two metal pins.

A LED plate is mounted on the driver plate (step 604) so that two outputterminals of the driver plate are electrically connected to the LEDplate.

A lens plate is placed (step 605) to a top peripheral end of the domeportion of the cup body.

In a specific example of the method, the cup body is made ofPolycarbonate material.

In a specific example of the method, the tube portion of the cup bodyhas a track trench for guiding and inserting the driver plate.

In a specific example of the method, the metal pins two metal pins aretwo metal hollow tubes, and the two input terminals of driver plate areinserted into the two metal hollow tubes.

In a specific example of the method, the lens plate has a central lensand a plurality of micro optical structures so that a portion of lightemitting from the LED plate running through the central lens of the lensplate to form a focus light beam and another portion of light emittingfrom the LED plate running through the plurality of micro opticalstructures to form soft light.

Please be noted that other variations based on the same inventive spiritshould be regarded falling within the protection scopes of the presentinvention. For example, the metal pins mentioned above may be designedas screw with associated screw grooves on the bottom portion of the cupbody. Other ways for integrating the metal pins with the bottom portionof the cup body may also be adopted under different design needs.

The embodiments mentioned above should not be interpreted as limitationfor the present invention. Persons of ordinary skilled in the art wouldbe able to create equivalent designs under protection scopes.

1. A spotlight apparatus comprising: a LED plate comprising a pluralityof LED modules, a metal plate and two connectors, the plurality of LEDmodules and the two connectors being mounted on the metal plate; a lensplate, comprising a central lens and a plurality of micro opticalstructures; a cup body comprising a dome portion, a tube portion and abottom portion, the dome portion and the tube portion being manufacturedtogether as a single body, the lens plate being fixed to a topperipheral end of the dome portion of the cup body, the LED plate beingdisposed inside the dorm portion so that a portion of light emittingfrom the LED modules running through the central lens of the lens plateto form a focus light beam and another portion of light emitting fromthe LED modules running through the plurality of micro opticalstructures to form soft light; a driver plate containing drivercircuits, two output terminals and two input terminals; and two metalpins integrated to the bottom portion of the cup body, the two inputterminals of the driver plate inserted into the two metal pins and thetwo output terminals connected to the LED plate.
 2. The spotlightapparatus of claim 1, wherein there is a neck portion between the dormportion and the tube portion, there is a first distance between wherethe LED plate is disposed and the neck portion, there is a seconddistance between the top peripheral and the neck portion, and the firstdistance is smaller than half of the second distance and larger than onefourth of the second distance.
 3. The spotlight apparatus of claim 1,wherein diffusion optical structures are formed on the dorm portion andthe tube portion.
 4. The spotlight apparatus of claim 1, wherein the twometal pins have openings respectively for receiving the two inputterminals of the driver plate.
 5. The spotlight apparatus of claim 4,wherein the two metal pins are metal hollow tubes.
 6. The spotlightapparatus of claim 4, wherein a portion of the input terminals of thedriver plate is deformed when the input terminals are inserted into theopenings of the two metal pins to keep better connection between theinput terminals and the two metal pins.
 7. The spotlight apparatus ofclaim 4, wherein the two metal pins are molded with the bottom portionof the cup body.
 8. The spotlight apparatus of claim 1, wherein the domeportion, the tube portion and the bottom portion of the cup body aretogether formed with Polycarbonate material as a single body.
 9. Thespotlight apparatus of claim 8, wherein the two metal pins are insertedin a molding device when the molding device is used for produce the cupbody so that the two metal pins are molded with the bottom portion ofthe cup body.
 10. The spotlight apparatus of claim 8, wherein the lensplate is made of Polycarbonate material as a single body.
 11. Thespotlight apparatus of claim 1, wherein the tube portion of the cup bodyhas a track trench for guiding and inserting the driver plate.
 12. Thespotlight apparatus of claim 11, wherein the driver plate has a baseplate with metal material for heat dissipation.
 13. The spotlightapparatus of claim 11, further comprising heat dissipation gel betweenthe track trench and the driver plate to enhance heat dissipation. 14.The spotlight apparatus of claim 11, further comprising heat dissipationglue between the track trench and the driver plate to enhance heatdissipation and connection reliability between the track trench and thedriver plate.
 15. The spotlight apparatus of claim 1, wherein the lensplate has a transparent hollow cup facing the LED modules.
 16. A methodfor manufacturing a spotlight apparatus, comprising: placing two metalpins in a molding device; forming a cup body with the molding device,wherein the cup body has a dorm portion, a tube portion and a bottomportion, the two metal pins are molded with the bottom portion; placinga driver plate in the cup body so that two input pins of the driverplate are inserted into the two metal pins; mounting a LED plate on thedriver plate so that two output terminals of the driver plate areelectrically connected to the LED plate; and mounting a lens plate to atop peripheral end of the dome portion of the cup body.
 17. The methodof claim 16, wherein the cup body is made of Polycarbonate material. 18.The method of claim 16, wherein tube portion of the cup body has a tracktrench for guiding and inserting the driver plate.
 19. The method ofclaim 16, wherein the metal pins two metal pins are two metal hollowtubes, and the two input terminals of driver plate are inserted into thetwo metal hollow tubes.
 20. The method of claim 16, wherein the lensplate has a central lens and a plurality of micro optical structures sothat a portion of light emitting from the LED plate running through thecentral lens of the lens plate to form a focus light beam and anotherportion of light emitting from the LED plate running through theplurality of micro optical structures to form soft light.